Electro-optic displays with edge seal components and methods of making the same

Abstract

An electro-optic display includes a backplane with at least one electrode, a layer of an electro-optic material disposed adjacent to the backplane, and a light-transmissive electrically-conductive layer disposed on the opposite side of the layer of electro-optic material from the backplane. The electro-optic display also includes a rod member disposed laterally adjacent to the backplane, the electro-optic material, and the light-transmissive electrically-conductive layer. A first barrier layer is disposed adjacent to the light-transmissive electrically-conductive layer and a first side of the rod member, and a second barrier is layer disposed on the backplane and a second side of the rod member. The second side is the opposite side of the rod member from the first side. A flexible barrier tape extends from an edge portion of the first barrier layer, around the rod member, to an edge portion of the second barrier layer.

1 . An electro-optic display comprising:
 a backplane comprising at least one electrode;   a layer of an electro-optic material disposed adjacent to the backplane;   a light-transmissive electrically-conductive layer disposed on the opposite side of the layer of electro-optic material from the backplane;   a rod member disposed laterally adjacent to the backplane, the layer of an electro-optic material, and the light-transmissive electrically-conductive layer;   a first barrier layer disposed adjacent to the light-transmissive electrically-conductive layer and a first side of the rod member;   a second barrier layer disposed on the backplane and a second side of the rod member, the second side being the opposite side of the rod member from the first side; and   a flexible barrier tape extending from an edge portion of the first barrier layer, around the rod member, to an edge portion of the second barrier layer.   
     
     
         2 . The electro-optic display of  claim 1  further comprising an edge sealing material within the flexible barrier tape, the edge sealing material being disposed:
 at a first end of the rod member adjacent to a first corner of the electro-electro-optic display, and 
 at a second end of the rod member adjacent to a second corner of the electro-electro-optic display. 
 
     
     
         3 . The electro-optic display of  claim 2  wherein the edge sealing material is a UV-curable resin. 
     
     
         4 . The electro-optic display of  claim 2  wherein the edge sealing material has a water vapor transmission rate between 2-3 g/m 2 /day at 60° C. and 90% relative humidity. 
     
     
         5 . The electro-optic display of  claim 1  wherein the barrier tape further comprises an adhesive layer on a surface of the barrier tape that contacts the edge portion of the first barrier layer, the rod member, and the edge portion of the second barrier layer. 
     
     
         6 . The electro-optic display of  claim 1  wherein the rod member is cylindrical and has an average diameter of between about 0.254 mm and about 2.54 mm. 
     
     
         7 . The electro-optic display of  claim 5  wherein the rod member is integrated into the barrier tape. 
     
     
         8 . The electro-optic display of  claim 7  wherein the rod member is positioned substantially along a lengthwise center portion of the barrier tape. 
     
     
         9 . The electro-optic display of  claim 1  wherein the barrier tape further comprises a layer of electrically insulating material disposed on a surface of the barrier tape that contacts the edge portion of the first barrier layer, the rod member, and the edge portion of the second barrier layer. 
     
     
         10 . The electro-optic display of  claim 1  wherein the barrier tape further comprises a metal foil layer disposed on a surface of the barrier tape opposite the surface that contacts the edge portion of the first barrier layer, the rod member, and the edge portion of the second barrier layer. 
     
     
         11 . The electro-optic display of  claim 1  wherein the barrier tape comprises a layer of adhesive material disposed on a first half of a lengthwise surface of the barrier tape and a layer of metal foil disposed on a second half of the lengthwise surface of the barrier tape. 
     
     
         12 . The electro-optic display of  claim 1  wherein the barrier tape comprises a colorant. 
     
     
         13 . An electro-optic display comprising:
 a backplane comprising at least one electrode;   a layer of electro-optic material disposed adjacent to the backplane;   a light-transmissive electrically-conductive layer disposed on the opposite side of the layer of electro-optic material from the backplane; and   a corner barrier seal disposed at each corner of the electro-optic display, the corner barrier seal comprising:
 a barrier material comprising a square shape in an unfolded state; 
 first, second, and third fold lines, 
 wherein the first and second fold lines are perpendicular to each other and the third fold line is substantially 45 degrees from the first and second fold lines, and 
 wherein the first, second, and third fold lines bisect one another and the barrier material; and 
   the first and second fold lines being folded in an upward direction, and the third fold line being folded in a downward direction forming first and second corner pockets.   
     
     
         14 . The electro-optic display of  claim 13  further comprising forming the square-shaped barrier material into an X-shape in the unfolded state. 
     
     
         15 . The electro-optic display of  claim 13  wherein the corner barrier seal further comprises an adhesive layer disposed on an inner surface of the first and second corner pockets. 
     
     
         16 . The electro-optic display of  claim 13  wherein:
 the layer of electro-optic material and the light-transmissive electrically-conductive layer are disposed within the first corner pocket of each corner barrier seal, and 
 the backplane is disposed within the second corner pocket of each corner barrier seal. 
 
     
     
         17 . The electro-optic display of  claim 13  wherein:
 the layer of electro-optic material, the light-transmissive electrically-conductive layer, and the backplane are disposed within the first corner pocket or the second corner pocket of each corner barrier seal. 
 
     
     
         18 . The electro-optic display of  claim 13  further comprising:
 a first barrier layer disposed on the light-transmissive electrically-conductive layer and a first surface of each corner barrier seal; and 
 a second barrier layer disposed on the backplane and a second surface of each corner barrier seal. 
 
     
     
         19 . The electro-optic display of  claim 18  wherein the first and second barrier layers are larger in both dimensions than the light-transmissive electrically-conductive layer, the layer of electro-optic material, and the backplane so as to leave peripheral portions of the first and second barrier layers extending beyond the edges of the light-transmissive electrically-conductive layer, the layer of electro-optic material, and the backplane respectively, and wherein the peripheral portions of the first and second barrier layers are secured to each other, thereby sealing the edges of the electro-optic display. 
     
     
         20 . The electro-optic display of  claim 18  further comprising:
 an edge sealing component extending around the periphery of the electro-optic display over an edge portion of the first barrier layer and an edge portion of the second barrier layer. 
 
     
     
         21 . The electro-optic display of  claim 18  wherein the edge sealing component is a barrier tape comprising polychlorotrifluoroethylene or aluminum oxide. 
     
     
         22 . A process for forming an electro-optic display, the process comprising:
 providing a front plane laminate comprising a layer of electro-optic material and a light-transmissive electrically-conductive layer;   providing a backplane comprising at least one pixel electrode, wherein the backplane is larger in length and width dimensions than the front plane sub-assembly;   laminating the front plane sub-assembly to the backplane;   dispensing a curable edge seal material around the periphery of the backplane adjacent to the outer edges of the front plane sub-assembly;   partially curing the curable edge seal material;   laminating a barrier layer over the front plane sub-assembly and partially-cured edge seal material, the barrier layer being sized to overhang the partially-cured edge seal material;   adhering an overhanging portion of the barrier layer to the surface of the backplane; and   fully curing the curable edge seal material.   
     
     
         23 . The process of  claim 22  wherein a surface of the barrier layer comprises a layer of pressure sensitive adhesive. 
     
     
         24 . The process of  claim 22  wherein partially curing the curable edge seal material comprises curing the curable edge seal material for between about 15 to 40 seconds. 
     
     
         25 . The process of  claim 22  wherein the curable edge seal material has a water vapor transmission rate between 2-3 g/m 2 /day at 60° C. and 90% relative humidity. 
     
     
         26 . The process of  claim 22 , wherein the curable edge seal material is a polymer comprising epoxies, urethanes, acrylates, or a combination thereof. 
     
     
         27 . The process of  claim 22 , wherein the curable edge seal material is UV-curable. 
     
     
         28 . An electro-optic display formed using the process of  claim 22 .